377 of the
2,964 complaints filed about the Chevrolet Volt
are about the engine —
13% of everything owners reported.
The worst model year for it is 2017.
While driving on a highway the car started to hesitate, a message appeared on the console "Propulsion power is reduced" and the engine light turn on. After driving some miles, a new message appeared: "Engine unavailable, service soon" and the car only ran on electric power, no motor engine. I had the same problem 3 year ago and the dealer identified the problem as a shorted EGR valve. This time I knew this shorted EGR valve burns the F3 fuse. I managed to get to a car part shop and bough several fuses (15 amp). After replacing the fuse 3 times I managed to get to the dealer. The repairs cost $3000+ (up from $1000+ 3 years ago). This problem is well documented on the GM service technical bulletin "21-NA-116" dated February, 2023. Three years ago I was in the middle of nowhere in South Texas and it took 6 hours to get a tow truck This time I was lucky enough to be close to to a town that the remain battery power was enough to get to the store where I bought the fuses. GM should recall this part and do a proper fix
NHTSA complaint #11755062 — an unverified report by a vehicle owner.
Received "reduced propulsion" message, with no engine detected. Car slowed to a near stop while driving on the Interstate highway. Very dangerous to have that suddenly happen. Message popped up randomly with no prior warning.
NHTSA complaint #11745522 — an unverified report by a vehicle owner.
Brought car into Chevrolet dealership for intermittent “miss” when driving. Dealer diagnosed it needed an EGR valve replaced at a cost of around $4,000.00 which is a significant portion of the cars value.
NHTSA complaint #11726050 — an unverified report by a vehicle owner.
The contact owns a 2017 Chevrolet Volt. The contact stated that while driving at an undisclosed speed or while starting the vehicle, the check engine warning light was unexpectedly illuminated. Additionally, there were several error codes provided through the Mobile App for engine-related failures. The dealer was contacted; however, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The approximate failure mileage was 92,000.
NHTSA complaint #11724699 — an unverified report by a vehicle owner.
I am reporting a series of safety concerns regarding my 2017 Chevy Volt, which have persisted despite multiple attempts to address them with the dealership. These issues pose significant risks to my safety and that of others on the road. On January 18th, 2024, I brought my vehicle to the dealer after experiencing reduced propulsion power while driving on the highway, coupled with the illumination of the check engine light. The mechanic performed a quick inspection and used a GM scan tool to diagnose the issue, revealing the code P1E00 for the Hybrid Powertrain Control Module 2, which was cleared without a thorough investigation. I was advised to return if the issue reoccurred. Despite the reset, the problem persisted, and on February 9th, 2024, I scheduled another appointment due to my Chevy Volt's High Voltage battery charging only to 65% capacity despite indicating a full charge. Subsequently, on February 11th, 2024, the check engine light illuminated again, and on February 12th, 2024, November 25th, 2025, January 11th, 2026, and February 12, 2026 while driving to work, both times I experienced a loss of propulsion power on the highway, placing my safety at risk and lost all power in a traveling lane of traffic. These ongoing issues with propulsion power and the high-voltage battery charging system are not only inconvenient but also potentially dangerous. Despite multiple visits to the dealership and attempts to diagnose and resolve the problem, it persists, indicating a systemic issue that requires immediate attention. The reduced propulsion power while driving on the highway, coupled with the illumination, I urge the National Highway Traffic Safety Administration (NHTSA) to investigate this matter thoroughly to ensure the safety of Chevy Volt drivers and passengers. It is imperative that General Motors addresses these issues promptly and implements appropriate measures to prevent further incidents.
NHTSA complaint #11718741 — an unverified report by a vehicle owner.
Several years ago, when I was driving the vehicle, I got a sudden "reduced propulsion alert" and the onboard coolant temperature gauge showed a significant spike in temperature. To avoid overheating, I had to pull over on the side of the highway. In the onboard fuse box, there was a blown F3 fuse. I replaced the fuse and the same issue happened again last year. After some online research, it is clear that the EGR valve failed. Unplugging the valve and replacing the fuse has returned the vehicle to normal operations, but it's now out of compliance with local emissions regulations. GM has failed to properly produce replacement parts. As of Feb 11, 2026, a local GM dealer in Bloomington, IN quoted a backorder and unclear wait time on a replacement part and quoted me at $2,000+ just for the part. If not for my quick thinking, this part failure could have overheated my vehicle causing extensive damages. GM has failed to produce enough replacement parts and given the safety issues associated with a blown fuse and overheating, NHTSA should order a recall on this part and force GM to replace the parts for owners. This is a widespread problem documented among Volt owners, and the only stopgap issue is to drive the vehicle out of compliance with local emissions rules.
NHTSA complaint #11717254 — an unverified report by a vehicle owner.
The engine light came on, but the car would run and so took it to the dealer. They determined that the EGR valve had failed and would cost $2400 to repair. Apparently, this is a common failure point for Generation 2 Chevy Volts. If it might trigger a forced recall, I'd like to add this to the list.
NHTSA complaint #11717029 — an unverified report by a vehicle owner.
It was the XXX recall for the DTC P0442/check engine light code. The dealership said that the recall had been satisfied in 6/2020 by putting a buffer in to separate the 2 lines but not replacing the part. Now the exact same code DTC P0442/check engine light in the exact spot that occurred for the original recall. The dealership originally quoted $5,093, then after me complaining that it is the same recalled problem they dropped the cots to $2384. I believe that is an agreement that the manufacturer should cover this. Of course I will have to pay to get my car but I would like the manufacturer to reimburse me for it seeing it was a manufacturer default. I spoke to the manufacturer they flat out refused to cover it. I obviously disagree. Would like you to pressure them to change their decision. Thank you, [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11716611 — an unverified report by a vehicle owner.
I received the "Propulsion Power is Reduced" Alert engine light while driving in "Normal" mode on the freeway at around 60mph with 8-9 miles of Battery capacity, it showed 0 miles of Battery forcing the Gas Engine on and the vehicle hesitated upon applying the accelerator for the remainder of the drive. My safety and that was others was at risk because the acceleration dropped quickly and I was on a busy freeway at the time when the Alert happened causing further hesitation. Upon stopping I could not get the vehicle to take a charge nor would it start up until a mechanic arrived and was able to confirm the problem.
NHTSA complaint #11715715 — an unverified report by a vehicle owner.
I am reporting a series of safety concerns regarding my 2017 Chevy Volt, which have persisted despite multiple attempts to address them with the dealership. These issues pose significant risks to my safety and that of others on the road. On January 18th, 2024, I brought my vehicle to the dealer after experiencing reduced propulsion power while driving on the highway, coupled with the illumination of the check engine light. The mechanic performed a quick inspection and used a GM scan tool to diagnose the issue, revealing the code P1E00 for the Hybrid Powertrain Control Module 2, which was cleared without a thorough investigation. I was advised to return if the issue reoccurred. Despite the reset, the problem persisted, and on February 9th, 2024, I scheduled another appointment due to my Chevy Volt's High Voltage battery charging only to 65% capacity despite indicating a full charge. Subsequently, on February 11th, 2024, the check engine light illuminated again, and on February 12th, 2024, November 25th, 2025, and January 11th, 2026, while driving to work, both times I experienced a loss of propulsion power on the highway, placing my safety at risk and lost all power in a traveling lane of traffic. These ongoing issues with propulsion power and the high-voltage battery charging system are not only inconvenient but also potentially dangerous. Despite multiple visits to the dealership and attempts to diagnose and resolve the problem, it persists, indicating a systemic issue that requires immediate attention. The reduced propulsion power while driving on the highway, coupled with the illumination I urge the National Highway Traffic Safety Administration (NHTSA) to investigate this matter thoroughly to ensure the safety of Chevy Volt drivers and passengers. It is imperative that General Motors addresses these issues promptly and implements appropriate measures to prevent further incidents.
NHTSA complaint #11710367 — an unverified report by a vehicle owner.
The contact owns a 2018 Chevrolet Volt. The contact stated that the battery module became inoperable. While attempting to start the vehicle, the message "Engine Unavailable - Service Soon” was displayed. The contact was unable to use the vehicle. The contact stated that the TPMS warning light was illuminated. The contact associated the failure with Technical Service Bulletin: 18-NA-261. The contact called the local dealer and was referred to the manufacturer for assistance. The vehicle was not diagnosed or repaired. The manufacturer was contacted and confirmed that the VIN was not under recall. The failure mileage was approximately 111,000.
NHTSA complaint #11705567 — an unverified report by a vehicle owner.
The contact owns a 2013 Chevrolet Volt. The contact stated that while driving at approximately 45 MPH, the vehicle stalled. The Check Engine warning light was flashing, and the messages "No Propulsion Power" and "No Power To Engine" were displayed. The contact stated that two individuals pulled over and assisted the contact in pushing the vehicle to the side of the road to prevent a crash. The vehicle was towed to an independent mechanic, who made the contact aware of an unknown NHTSA Campaign Number; however, the VIN was not included. The vehicle was towed to a dealer, but the vehicle was not diagnosed or repaired. The contact requested vehicle rental assistance, but the dealer was unable to provide assistance. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance in initiating a recall. The failure mileage was approximately 141,323.
NHTSA complaint #11705337 — an unverified report by a vehicle owner.
Component/System Failed: The engine of my 2016 Chevrolet Volt experienced a sudden internal crack, leading to complete engine failure. The engine is available for inspection upon request. Safety Risk: The engine failure rendered the vehicle completely inoperable, posing potential risk if it had occurred while driving. Sudden loss of engine power could have caused a crash or left me stranded in traffic, endangering myself and others. Problem Reproduction / Confirmation: The failure was confirmed by a GM dealership, which performed a full inspection and documented the engine crack. The dealership verified that the crack was sudden and not caused by negligence or improper maintenance. Inspections by Others: The vehicle has been inspected by the dealership, and all reports are available. I have also submitted the issue to GM corporate for warranty review. No police or insurance representatives have reviewed this, as this was a mechanical failure with no collision. Warning Lamps or Symptoms: No warning lights, messages, or unusual symptoms appeared prior to the failure. The engine appeared to operate normally until the sudden failure. Upon failure, low oil and low propulsion error message appeared on dash. Current no dash lights are on in the vehicle. Assessment of Cause: Based on dealership inspection and documentation, the failure appears sudden and possibly related to a defect in emissions-related engine components. No external damage or user error contributed to the failure.
NHTSA complaint #11703409 — an unverified report by a vehicle owner.
My 2015 Chevy Volt has been experiencing ongoing mechanical and electrical issues, including random power loss, reduced propulsion warnings, and sudden vehicle shutdowns with no prior indication. These problems pose a serious safety concern, as the car can lose power unexpectedly while driving. Despite these issues, GM has refused to service the vehicle or unlock necessary components because they no longer manufacture or support the required parts. As a result, I am left with an unsafe and unreliable vehicle with no available remedy from the manufacturer. This is forcing me to trade in the vehicle at a loss
NHTSA complaint #11699358 — an unverified report by a vehicle owner.
My wife and I were on a 200 mile trip and the engine failed about 150 miles into the trip. Was driving and the instrument panel indicated that the engine was in reduced power mode. I switched over to battery power but had only approximately 10 miles of range left so after a couple of miles I switched back to engine power and was almost immediately informed by the instrument panel that the engine was in failure mode. Was fortunate that there was an exit nearby and was able to use the remaining battery power to exit the highway and pack the car before there was no power.the car was towed to a dealer and we were told that the egr valve and cooler had failed.they were replaced and I was told that they were not covered by the federal emissions warranty so the cost would be $4000.the car was driven with the vast majority being electric power.
NHTSA complaint #11695779 — an unverified report by a vehicle owner.
The EGR valve clogged, causing a a servo to blow the F3 fuse, disabling the engine while driving. This occured suddenly while driving on a busy road with no shoulders. I managed to coast into a parking lot not too far away but I had no charge left in my battery. I could only get the engine to start back up for less than a minute at a time. I got my car inspected by Chevrolet and they confirmed they issue. Very shortly before the engine cut off, the car started jolting. There weren't any warning lights or error codes before this.
NHTSA complaint #11693733 — an unverified report by a vehicle owner.
EGR valve and EGR cooler failure. Engine power was reduced and EGR fuse kept blowing. Has code for EGR flow failure/restriction. Check engine light remains on even when reset
NHTSA complaint #11692768 — an unverified report by a vehicle owner.
My EGR system caused a check engine light. P0401 This is an extremely well documented issue on Gen2 Volts, especially 2017 models. Simply searching "EGR" on the Volt subreddit or forums returns hundreds of related threads. This issue can lead to a clogged EGR valve, causing further damage. A temporary resolution is unplugging the EGR valve, which i have not yet done. But this leaves the CEL illuminated, and without daily scanner, I wouls not know if other issues arise, causing a significant safety hazard.
NHTSA complaint #11692401 — an unverified report by a vehicle owner.